Filler apparatus with hopper and rotary feed mechanism for dispensing controlled volumes of materials

ABSTRACT

Apparatus for dispensing controlled volumes of materials from a hopper using a rotary feed mechanism incorporates a digital count controller responsive to a signal generator that generates digital signals in direct relation to the rotary displacement of the feed mechanism.

United States Patent [191 Sauerbrey FILLER APPARATUS WITH HOPPER ANDROTARY FEED MECHANISM FOR DISPENSING CONTROLLED VOLUMES OF MATERIALS[75] Inventor: Charles A. Sauerbrey, Malverne, Pa. [73] Assignee: G.Dlehl Mateer Co., Wayne, Pa. [22] Filed: Dec. 21, 1970 [21] Appl. No;99,789

[52] US. Cl 222/63, 222/70, 222/76 [51] Int. Cl. 367d 5/14 [58] Field ofSearch 222/63, 70, 76, 378,

222/413; 14l/l92;-226/9; 235/98 C, 132 E; 198/40 [56] References CitedUNITED STATES PATENTS 3,305,133 2/1967 Parker 222/70 IF DIGITAL 7567cou/vrn? July 3,1973

Rappaport et a1. 235/98 C X Primary Examiner-Samuel F. Coleman AssistantExaminer-Norman L. Stack, Jr. Attorney-Seidel, Gonda & Goldhammer [57ABSTRACT Apparatus for dispensing controlled volumes of materials from ahopper using a rotary feed mechanism incorporates a digital countcontroller responsive to a signal generator that generates digitalsignals in direct relation to the rotary displacement of the feedmechanism.

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INVENTOI? CHARLES A. SA UERBRE'Y ATTORNEYS FILLER APPARATUS WITH HOPPERAND ROTARY FEED MECHANISM FOR DISPENSING CONTROLLED VOLUMES OF MATERIALSThis invention relates to filler apparatus for dispensing controlledvolumes of material using a hopper and rotary feed mechanism. Moreparticularly, this invention relates to a filler apparatus foraccurately dispensing controlled volumes of materials into containers bycontrolling the feed mechanism through digital techniques.

The basic concept of accurately filling containers by dispensingmaterials from a conical hopper using a retary feed mechanism is wellknown. See, for example, US. Pat. Re. No. 23,888 and Re. No. 24,079.Apparatus such .as is shown in these patents can be used for volumetricfilling of free-flowing and non-free-flowing granular, powdered, flakedor paste material. Typically, the feed mechanism is positioned in anopening in the bottom of a conical hopper and consists of either anauger or a pump such as a Moyno pump. The auger, pump rotor, or otherrotational member is driven by a prime mover (such as an electric motor)through a clutch-brake mechanism which connects a driving shaft to adriven shaft. The clutch-brake mechanism is controlled to rotate thedriven shaft for a pre-selected number of revolutions by an analogdevice which counts the number of revolutions. This is a relativelyaccurate way of volumetrically dispensing material since the amount ofmaterial dispensed by each revolution of the auger or pump is known. Forexample, for each revolution of an auger of known pitch and diameter,the volume of material dispensed from its discharge end is known. Byappropriate control, the auger can be made to run through sequentialcycles of a predetermined number of turns. During each cycle, apredetermined volume of material is discharged into a containerpositioned by mechanized packaging devices beneath the discharge end ofthe feed mechanism. Mechanized packaging line devices for sequentiallypositioning containers made of paper, metal, plastic or glass are wellknown.

Since each revolution of the feed mechanism dispenses a known amount ofmaterial, it follows that the number of revolutions is a measure of thevolume of material that has been dispensed. There are two methods fordetermining the number of revolutions. The first method is to directlycount the number of revolutions. The second method is to measure thetime period over which the feed mechanism is being driven at a constantspeed. In known apparatus, devices for counting the number ofrevolutions normally incorporate a counter directly linked by gearing tothe output side of the clutch-brake mechanism mentioned above. Suchdevices permit the operator to preset a graduated dial to the desirednumber of revolutions. A compound train of spur and helical gearstransmit rotational movement from the output side of the clutch-brakemechanism to a revolution count control switch. When the correct countis reached, the driven shaft is disengated from the driving shaft andbrought immediately to a stop by the clutch-brake mechanism. Althoughsuch mechanisms are manufactured with precision and assembled withsevere quality monitoring, inherent errors make the repetitive accuracyof performance within the range of plus or minus 0.001 to 0.0025percent.

The timed method of controlling the number of revolutions is lessaccurate. Experience has shown that direct coupling to the driven memberof the feed mechanism is the most accurate way of measuring countrevolutions.

The present invention is directed to an apparatus for enhancing theaccuracy of such apparatus for dispensing controlled volumes ofmaterials. In particular, the present invention retains the direct,positive coupling of a revolution counting mechanism, but improves uponit by incorporating a digital technique. As an improved apparatus forcontrolling the number of revolutions of the rotary feed mechanism, adevice for generating digital signals is directly coupled to the drivenmember of the feed mechanism. These digital signals are detected andcounted. Such signals are accurate indications of the amount ofrevolution of the driven shaft. Hence, an appropriate count of digitalsignals is also a count of the number of revolutions or partialrevolutions of the shaft. When an appropriate pre-set count has beenreached, the clutch-brake mechanism can be operated in the conventionalmanner to stop the driven member of the feed mechanism.

It is an object of the present invention to provide an improved fillerapparatus with hopper and rotary feed mechanism for dispensingcontrolled volumes of materials.

It is another object of the presentinvention to provide an improvedfiller apparatus with hopper and rotary feed mechanism for dispensingcontrolled volumes of materials that incorporates digital techniques forcontrolling the number of revolutions of the feed mechanism.

Yet another object of the present invention is to provide a moreaccurate filler apparatus with hopper and rotary feed mechanism fordispensing controlled volumes of materials.

Other objects will appear hereinafter.

For the purpose of illustrating the invention, there is shown in thedrawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

FIG. 1 is a schematic block diagram illustrating the functional elementsof the filler apparatus.

FIG. 2 is a partial sectional view of the filler apparatus.

FIG. 3 is a sectional view of the tiller apparatus illustrated in FIG. 2taken along the line 3-3 to show the light chopping disc.

Referring now to the drawings in detail, wherein like numerals indicatelike elements, there is shown in FIG. 1 a filler apparatus with hopperand rotary feed mechanism for dispensing controlled volumes ofmaterials, designated generally as 10. The apparatus is shownschematically and in block diagram form for purposes of illustrating theinvention.

FIG. 2 illustrates by way of example, a typical filler apparatus ascomprising a hopper 12, which preferably is conical, supported byappropriate brackets and straps 14 and 16 on the column 18.

The plate 20 is mounted on the top of column 18 and supports by means ofappropriate fasteners the motor 22 and the drive train 24. The motor 22may be any form of well known prime mover such as an electric motor oreven a hydraulic motor, although it is preferably an electric motor. Thedrive train may consist of an assemblage of belts and pulleys or, in thealternative, a gear train or transmission adapted to rotate the drivingshaft 26. The driving shaft, or its equivalent, may be referred tohereinafter as a driving member.

The driving shaft 26 serves to couple the drive train 24 to the inputside of the brake-clutch mechanism 28. The brake-clutch mechanism 28serves to selectively connect the driving member 26 which takes the formof a drive shaft to the driven member 30 which in this case is a shaftconnected to the auger 32. The brakeclutch mechanism may be aconventional mechanism such as the one described in U.S. Pat. Re. No.23,888. Of course, other types of brake-clutch mechanisms which functionto provide rotational control for the driven shaft 30 and hence theauger 32 may be provided.

As shown, the auger 32 is fitted within the dispensing nozzle 34 at theopen bottom end of the hopper 12. R- tation of the auger 32 causesmaterial 36 to be dis placed from the hopper 12 through the nozzle 34into containers sequentially positioned by a mechanism (not shown)beneath the hopper. It should be understood that by illustrating anauger, there is no intention to limit the invention. For example, theauger 32 could be replaced by the screw rotor of a Moyno pump such as isillustrated in U.S. Pat. Re. No. 24,079.

Also fixed to the shaft 30 so as to be rotative with it is a disc 38.The function of the disc 38 is to act as a light chopper. For thispurpose, it is provided with a plurality of slots 40 evenly spaced aboutits periphery. The number of slots 40 can be varied. However, forconvenience a preferred embodiment may have 100 slots, thereby providinga number that is divisible by to indicate a complete revolution of theshaft 30 and hence the auger 32.

A bracket 42 supports a signal source 44. The source 44 may be thefilament of an incandescent lamp or a gaseous lamp which is suppliedwith a steady electric current so as to generate a steady state lightsource. The bracket 42 also supports a photoconductive transducer 46,such as a phototransistor or the like, which is sensitive to the signalenergy generated by the source 44.

The source 44 and photoconductive transducer 46 are positioned by thebracket 42 in opposing relation adjacent the peripheral edge of the disc38. Thus, signal energy emitted by the source 44 must pass through theslots 40 and the disc 38 in order to be detected by the photoconductivetransducer 46. This is best illustrated in FIG. 3. As a result, theoutput of the photoconductive transducer 46 is a series of discreteelectrical pulses whose frequency will depend upon the speed at whichthe shaft 30 is rotating.

It should be understood that the illustrated embodimentof disc 38 as alight chopper and the photoconductive transducer 46 is by way ofexample, not limitation. Obviously, other structure could be used. Forexample, the disc could be made stationary and the photoconductivetransducer 46 rotated relative to the disc. The result would still bethe generation of a series of discrete pulses generated by the blockingand unblocking of a light path for the source 44 directed toward thephotoconductive transducer 46. Still further, the slots 40 could bedetected by other devices to generate discrete electrical pulses. Amongsuch devices are pneumatic or magnetic transducers, or mechanicalswitches, proximity sensors or other devices that generate a signalpulse corresponding to the relative displacement of rotating slots onthe disc 38.

Referring now to FIG. 1, there is shown in schematic block form theelements of the circuitry for counting and controlling the number ofrotations of the auger 32. As shown, the output of the photoconductivetransducer 46 is connected through switch 48 to a wave shaping network50. Wave shaping network 50 provides appropriate filters and clampingdevices to shape the pulses generated by the light chopper 38 andphotoconductive transducer 46 so that they may be processed by thedigital counter 52. The output of the wave shaping network 50 isconnected to the digital counter 52 which counts the number of discretepulses. Digital counters are well known and hence need not be describedin detail. Each pulse is a signal counted by the counter 52, and eachsignal represents a known unit of displacement of the shaft 30 becausethe slots 40 are uniformly spaced about its periphery. Hence, a specificcount registered in the digital counter 52 represents a specific numberof turns or partial turns of the auger 32.

The output of digital counter 52 is connected to the preset control 54which operates in conjunction with the digital counter 52. The functionof the preset control 54 is to generate a control signal when the countin digital counter 52 reaches a predetermined amount. Preset control 54is calibrated in turns and partial turns so that an operator can set inthe volume of material to be delivered by the auger 32.

When the count in digital counter reaches the preset amount in control54, an output signal is generated and transmitted to the output control56. Output control 56 responds by generating a signal which in turn istransferred to the rotational control 28. In the illustrated embodiment,the rotational control is a clutch-brake 28. The clutch-brake 28responds by disengaging driving member 26 from the driven member 30 andby bringing the driven member 30 to an immediate halt.

A power supply 60 is shown for providing power to each of the elementsof the block diagram. I

From the foregoing, it may be seen that a direct, positive method ofcounting the revolutions has been provided. However, in this instancethe method is digital rather than analog. Therefore, this system is nolonger dependent upon interpreting mechanical or electrical resolutionchains to determine the number of revolutions. Instead, a precise,closely coupled and direct system is provided. The end result is a muchmore accurate control over the volume of material delivered out of thehopper 12 by the feed mechanism consisting of auger 32 and nozzle 34.

Apparatus 10 such as has been described can be used in processes fordispensing dry, moist or liquid products where the delivered quantity ofmaterial exceeds the volume normally dispensed by existing apparatus. Byway of example, existing apparatus is normally used to fill smallcontainers ranging from one-half ounce to one hundred pounds maximum.Existing analog devices for counting the number of revolutions of theauger are limited to a range of approximately revolutions.

Such apparatus would be inadequate if more than 120 revolutions of theauger 32 are required to dispense the material of a desired volume, suchas into a convention 55 gallon steel drum having a restricted bung holeopening. To fill such a container would require several thousandrevolutions of the auger. The present invention can be used to fill sucha container.

The foregoing is accomplished by moving the switch 48 from theillustrated position to a position wherein the shaping network 50 isconnected to the filter 62. Filter 62 is in turn connected to rectifier46 which is connected to a source of alternating current at a knownfrequency. The rectifier 64 converts the alternating current into aseries of discrete, direct current signals which are filtered andapplied to the shaping network 50. Since the frequency of thealternating current is known, the number of signals generated per unittime is also known. As a result, the amount set in the preset control 54becomes a function of time of revolution of the shaft 30. Hence, theapparatus can be immediately converted over into a timed control type ofapparatus for filling large containers.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification as indicating the scope of theinvention.

I claim:

1. A filler apparatus of the type comprising a vertical hopper and arotary feed mechanism for dispensing controlled volumes of material intocontainers through an opening at the bottom of the hopper, said feedmechanism including a driven member and a driving member operated by aprime mover, rotary control means for selectively engaging anddisengaging said driving member with said driven member to start andstop the dispensing of materials from the hopper, and control means forcontrolling the number of revolutions of the driven member by causingsaid rotary control means to disengage said driving means from saiddriven means when said driven means has rotated through a predeterminednumber of revolutions, said control means including electro-opticalsignal generating means directly connected to said driven member forgenerating a series of digital signals proportional to the amount ofrotation of said driven member, counter means to count the number ofdigital signals generated, and count responsive control means connectedto be responsive to a preset count by said counter means to generate asignal to operate said rotary control means to disengage the drivingmember from the driven member when a preset count has been reached.

2. A filler apparatus in accordance with claim 1 wherein said signalgenerating means for generating digital signals comprises a lightchopper fixed to the driven member and a photodetector for detecting thesignal energy chopped by the light chopper and transducing said detectedenergy into digital signals.

3. In a filler apparatus in accordance with claim 2 wherein said countermeans to count the number of digital signals comprises a digitalcounter.

4. A filler apparatus in accordance with claim I including digitalsignal generating means to generate digital signals independent of saidsignal generating means for generating digital signals in response tothe rotation of said driven member, and means to connect saidindependent digital signal generator means directly to said countermeans to count the number of digital signals, and means to disconnectsaid signal generating means for generating digital signals in responseto rotation of said driven member from said counter means to count thenumber of digital signals.

Disclaimer 3,743,140.Charles A. Sauerbrey, Malvern, Pa. FILLER APPARATUSWITH HOPPER AND ROTARY FEED MECHANISM FOR DISPENS- ING CONTROLLEDVOLUMES OF MATERIALS. Patent dated July 3, 1973. Disclaimer filed May25, 1983, by the assignee, Berwind Corp. Hereby enters this disclaimerto claims 1-4 of said patent.

[Oflicial Gazette December 25, 1984.]

1. A filler apparatus of the type comprising a vertical hopper and arotary feed mechanism for dispensing controlled volumes of material intocontainers through an opening at the bottom of the hopper, said feedmechanism including a driven member and a driving member operated by aprime mover, rotary contrOl means for selectively engaging anddisengaging said driving member with said driven member to start andstop the dispensing of materials from the hopper, and control means forcontrolling the number of revolutions of the driven member by causingsaid rotary control means to disengage said driving means from saiddriven means when said driven means has rotated through a predeterminednumber of revolutions, said control means including electro-opticalsignal generating means directly connected to said driven member forgenerating a series of digital signals proportional to the amount ofrotation of said driven member, counter means to count the number ofdigital signals generated, and count responsive control means connectedto be responsive to a preset count by said counter means to generate asignal to operate said rotary control means to disengage the drivingmember from the driven member when a preset count has been reached.
 2. Afiller apparatus in accordance with claim 1 wherein said signalgenerating means for generating digital signals comprises a lightchopper fixed to the driven member and a photodetector for detecting thesignal energy chopped by the light chopper and transducing said detectedenergy into digital signals.
 3. In a filler apparatus in accordance withclaim 2 wherein said counter means to count the number of digitalsignals comprises a digital counter.
 4. A filler apparatus in accordancewith claim 1 including digital signal generating means to generatedigital signals independent of said signal generating means forgenerating digital signals in response to the rotation of said drivenmember, and means to connect said independent digital signal generatormeans directly to said counter means to count the number of digitalsignals, and means to disconnect said signal generating means forgenerating digital signals in response to rotation of said driven memberfrom said counter means to count the number of digital signals.